Search Results (32)

When using supplementary cementitious materials to replace cement partially, the carbon emissions of cement products can be reduced, but it often leads to reduced strength. This study explores the application potential of carbide slag (CS) and calcined coal gangue (CCG), byproducts of acetylene production, to partially replace cement. The effects of these two materials on the macroscopic properties and microstructure of cement-based materials were analyzed through systematic experiments. The compressive strength, ultrasonic pulse velocity, and electrical resistivity test results showed that replacing 20% of cement with CCG did not cause significant changes in the test results of the specimens. An X-ray diffraction (XRD) analysis showed that these two materials can produce additional hydration products. Scanning electron microscopy images (SEM) further revealed that CCG produces hydration products to fill microscopic pores. Thermogravimetric analysis (TG) results after 28 days showed that with the addition of supplementary cementitious materials, calcium hydroxide (CH) in CS reacts with CCG, resulting in the consumption of CS. Finally, the environmental impact of CS and CCG was assessed. It was found that CS is more favorable for reducing carbon emissions compared to CCG. However, when considering the effect of cement replacement on compressive strength, combining these two materials is more advantageous for sustainable development. Overall, the use of CS and CCG demonstrated good performance in promoting sustainable development. Full article

Coal mining and washing processes generate substantial amounts of coal gangue, posing significant environmental challenges. Coal gangue as a solid waste is rich in SiO₂ and Al₂O₃, with the SiO₂/Al₂O₃ molar ratio closely aligned with the ideal composition of 4A molecular sieves. In this study, through a synergistic pretreatment process involving low-temperature oxidation and hydrochloric acid leaching, the Fe₂O₃ content in coal gangue was reduced from 7.8 wt% to 1.1 wt%, markedly enhancing raw material purity. The alkali fusion–hydrothermal synthesis parameters were optimized via orthogonal experiments—calcination (750 °C, 2 h), aging (60 °C, 2 h), and crystallization (95 °C, 6 h) to maintain cubic symmetry, yielding highly crystalline 4A zeolite. Characterization via XRD, calcium ion adsorption capacity, SEM, and FTIR elucidated the regulatory mechanism of calcination on kaolinite phase transformation and the critical role of alkali fusion in activating silicon–aluminum component release. The as-synthesized zeolite exhibited a cubic morphology, high crystallinity, and sharp diffraction peaks consistent with the 4A zeolite phase. The pH of the zero point charge (pH_ZPC) of the 4A molecular sieve is 6.13. The 4A molecular sieve has symmetry-driven adsorption sites, and the adsorption of Cu²⁺ follows a monolayer adsorption mechanism (Langmuir model, R² = 0.997) with an average standard enthalpy change of 38.96 ± 4.47 kJ/mol and entropy change of 0.1277 ± 0.0148 kJ/mol, adhering to pseudo-second-order kinetics (R² = 0.999). The adsorption process can be divided into two stages. This study provides theoretical and technical insights into the high-value utilization of coal gangue. Full article

Coal gangue, a prevalent solid waste in the coal industry, has long been a significant concern due to its substantial production volume and potential environmental hazards. However, it contains valuable components such as silica and alumina, making it a promising raw material for synthesizing cementitious materials. This study focused on the synthesis of coal gangue-based magnesium silicate hydrate (M-S-H) and calcium silicate hydrate (C-S-H) through mechanical–thermal–chemical composite activation treatment. The cementitious activity of coal gangue samples and the characterization of the resulting cementitious materials were analyzed using ICP-AES, FTIR, XRD, SEM, and DSC-TG. Results indicated that calcination temperature, calcination time, the Ca/Si molar ratio, and the Mg/Si molar ratio were key factors influencing the cementitious activity of coal gangue, exhibiting a positive correlation with the dissolution amounts of Si⁴⁺ and Al³⁺. When kaolin in coal gangue was fully decomposed into active Al₂O₃ and SiO₂, the cementitious activity of coal gangue reached its peak. M-S-H and C-S-H were successfully synthesized after 7 days of curing at room temperature, significantly reducing the synthesis time. The synthesized M-S-H and C-S-H exhibited large specific surface areas, good mechanical properties, and well-developed pore structures, making them suitable as mesoporous materials that provide numerous active sites for adsorbing metal ions. Full article

To reduce solid waste production and enable the synergistic conversion of solid waste into high-value-added products, we introduce a novel, sustainable, and ecofriendly method. We fabricate nanofiber and nanosheet silicon carbides (SiC) through a carbothermal reduction process. Here, the calcined coal gangue, converted from coal gangue, serves as the silicon source. The carbon sources are the carbonized waste tire residue from waste tires and the pre-treated kerosene co-refining residue. The difference in carbon source results in the alteration of the morphology of the SiC obtained. By optimizing the reaction temperature, time, and mass ratio, the purity of the as-made SiC products with nanofiber-like and nanosheet-like shapes can reach 98%. Based on the influence of synthetic conditions and the results calculated from the change in the Gibbs free energy of the reactions, two mechanisms for SiC formation are proposed, namely the reaction of intermediate SiO with CO to form SiC-nuclei-driven nanofibrous SiC and the SiO-deposited carbon surface to fabricate nuclei-induced polymorphic SiC (dominant nanosheets). This work provides a constructive strategy for preparing nanostructured SiC, thereby achieving “turning trash into treasure” and broadening the sustainable utilization and development of solid wastes. Full article

To effectively solve the problem of land sanding and improve the water- and element-retaining properties of sandy soil, a thermal-activated coal gangue (TACG) was used as an ameliorating material to prepare a composite soil mixed with sandy soil to enhance the water-retaining and fertilizer-fixing properties of the sandy soil and reduce the evaporation of water in the soil. The structure and thermal stability of the gangue were characterized using Fourier transform infrared spectroscopy and thermogravimetric analysis. By applying different dosages and different calcination temperatures of the TACG, the water-holding capacity of the mixed soil was determined, and changes in pore structure were observed. When the dosage was 15% and the calcination temperature was 600 °C, the mixed soil possessed the most excellent distribution of pore structure and could effectively prevent water evaporation. Meanwhile, the application of the TACG in sandy soil improved its adsorption of K⁺, which showed the potential application of thermally activated gangue materials in the field of soil improvement. Full article

The recycling of coal gangue has considerable potential to produce secondary environmental hazards, which significantly influence the high-end application of coal gangue in practical engineering. The present study investigates the effects of activation treatment on the physical, chemical properties and leaching behavior of coal gangue. The mineral composition, micro-pore structure and element leaching were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), Thermogravimetry Analysis (TG), Low-Temperature Nitrogen Adsorption (LTNA) and Inductively Coupled Plasma (ICP). The results indicate that kaolinite and pyrite in coal gangue experienced reconstruction after 600 °C during thermal activation. The density of thermally activated coal gangue is increased with the calcination temperature as well as the alkalinity (from 4.8–7.1) due to the burning of organic and the oxidation of pyrite. The calcination treatment induced the reduction in macropore volume (>50 nm), and enhancement in mesopore (<5 nm) volume. Leachable Ni, Cd, Mn, Cu, Zn and Pd decreased by 99%, 67%, 86%, 40%, 99% and 93% after calcination at 800 °C, respectively. The Si and Al in 800 °C calcined coal gangue exhibited a high leaching ability in alkalinity solution; leachable Al reached 106.4 mg/kg, while leachable Si reached 86.1 mg/kg after 48 h of dynamic leaching. Full article

The impact of various modification methods on enhancing the adsorption performance of coal gangue (CG) for hazardous heavy metals has not been thoroughly investigated. In this study, three CG samples were first modified by calcination, followed by acid washing, alkali washing, and hydrothermal treatment, to obtain modified CG samples. The adsorption performance was assessed based on the adsorption capacities for Cd²⁺ and Pb²⁺ (i.e., q_e,Cd and q_e,Pb), and the kinetics of the adsorption processes were analyzed using kinetic equations. XRD, SEM-EDX, FTIR, and N₂ adsorption–desorption isotherms were used to elucidate the adsorption mechanisms. Results indicated that q_e,Cd and q_e,Pb of raw CG samples were approximately 10 and 25 mg/g, respectively, with only slight changes observed after calcination, acid washing, and alkali washing. In contrast, hydrothermal treatment yielded NaP and NaA zeolites, which significantly enhanced q_e,Cd and q_e,Pb to values of 48.5–72.7 and 214.9–247.5 mg/g, respectively. The hydrothermally treated CG samples primarily adsorbed Cd²⁺ and Pb²⁺ through ion exchange with Na⁺ within the zeolite structure, facilitating the entry of these ions into the zeolite’s pore channels. The adsorption processes were effectively described by the pseudo-second-order kinetic model. By optimizing the conditions of hydrothermal modification, the adsorption performance of CG samples is anticipated to further improve due to the creation of additional adsorption sites. Full article

This study focuses on the calcined coal gangue (CCG)-blended cements containing Stöber nano-SiO₂ (SNS) particles. The effects of SNS particles on the workability, hydration behaviour, mechanical properties and microstructure evolution of the blended cements were comprehensively investigated at curing ages ranging from 1 to 28 d. The hydration behaviour was studied via isothermal calorimetry test, X-ray diffraction (XRD) and thermogravimetric (TG) tests. The microstructural evolution was studied using mercury intrusion porosimetry (MIP) and scanning electron microscopy (SEM). The results show that the incorporation of SNS led to a significant reduction in fluidity, particularly at an SNS content of 3%. The SNS significantly increased the compressive strength of the CCG-blended cement at all curing ages, and the optimum SNS content was found to be 2%. SNS significantly accelerated not only the early cement hydration but also the pozzolanic reaction of CCG at later curing ages, resulting in a decrease in portlandite, as evidenced by the isothermal calorimetry, XRD and TG analysis. Microstructural analysis shows that the incorporation of SNS effectively refined the pore structure of the CCG-blended cement, resulting in the formation of a dense microstructure. All these beneficial effects of SNS provides advantages in the development of the compressive strength of the CCG-blended cement at all curing ages. Full article

The feasibility and performance of using calcined coal gangue (CCG) to substitute metakaolin (MK) as the precursor to prepare alkali-activated materials (AAMs) were thoroughly evaluated by conducting combined experiments of flowability test, mechanical measurement, calorimetry and microstructure analysis, etc. It was found that the increased substitution ratio of CCG to MK can increase the flowability of the prepared paste by up to 28.1% and decrease its viscosity by up to 55.8%. In addition, a prolonged setting time of up to 31.8% was found with the increased substitution amount of CCG to MK, which can be attributed to the low reactivity of CCG compared to that of MK. Lastly, even though the presence of CCG can lead to a decrease in the early compressive strength of the hardened paste, a highly recovered long-term mechanical property can be found due to the continuous reaction of CCG. All of these results prove the feasibility of using CCG as one co-blended precursor with MK to prepare alkali-activated materials. Full article

Aiming at the problems of the large storage, complex composition, low comprehensive utilization rate, and high environmental impact of coal gangue, this paper carried out experimental research on the preparation of iron oxide red from high-iron gangue by calcination activation, acid leaching, extraction, and the hydrothermal synthesis of coal gangue. The experimental results show that when the calcination temperature of coal gangue is 500 °C, the calcination time is 1.5 h, the optimal concentration of iron removal is 6 mol/L, the acid leaching temperature is 80 °C, the acid leaching time is 1 h, and the liquid——solid mass ratio is 4:1; the iron dissolution rate can reach 87.64%. A solvent extraction method (TBP-SK–hydrochloric acid system) was used to extract the leachate, and a solution with iron content up to 99.21% was obtained. By controlling the optimum hydrothermal conditions (pH = 9, temperature 170 °C, reaction time 5 h), high-purity iron oxide red product can be prepared; the yield is 80.07%. The red iron oxide was characterized by XRD, SEM-EDS, particle-size analysis, and ICP-OES. The results show that the red iron oxide peak has a cubic microstructure, an average particle size of 167.16 μm, and a purity of 99.16%. The quality of the prepared iron oxide red product meets the requirement of 98.5% of the “YHT4 Iron oxide Standard for ferrite”. It can be used as a raw material to produce high-performance soft magnetic ferrite. In summary, this experimental study on the preparation of iron oxide red from coal gangue is of great significance for the comprehensive utilization of coal gangue to realize the sustainable development of the environment and economy. Full article

The utilization of calcined coal gangue (CCG) and limestone for the preparation of blended cement is an efficient approach to address the issue of coal gangue disposal. However, the compressive strength development of blended cement is slow, particularly at high substitution levels of CCG. Therefore, this study aimed to promote the hydration and mechanical properties of the calcined coal gangue–limestone blended cements by increasing the curing temperature. In this study, the samples were cured at two different temperatures, namely 20 and 40 °C. The four groups of samples contained 15 wt.%, 30 wt.%, 45 wt.% and 60 wt.% cement substitutions using CCG and limestone (2:1 mass ratio). The compressive strength, hydration and microstructure were investigated at the ages of 1 to 28 d. X-ray diffraction (XRD) and thermogravimetry (TG) were used to study the hydration behavior of samples. Mercury intrusion porosimetry (MIP) and scanning electron microscopy (SEM) were used to determine the microstructure of the samples. The results indicate that an increase in curing temperature significantly promotes the compressive strength of the calcined coal gangue–limestone blended cements from 1 to 28 d. The microstructural analysis indicates that increasing the curing temperature not only promotes cement hydration but also facilitates the reaction of CCG, which precipitated more hydrates such as C-A-S-H gel, Hc and Mc. These hydrates are conducive to refining the pore structures and densifying the microstructure, which sufficiently explains the enhanced compressive strength of the calcined coal gangue–limestone blended cements. Full article

Coal gangue (CG) is a residual product from coal mining and washing processes. The reutilization of CG to produce geopolymers is a low-carbon disposal strategy for this material. In this study, the calcined CG (CG_700°C) was used as aluminosilicate precursors, and the effects of alkali activators (i.e., Na₂SiO₃/NaOH, NaOH concentration, and liquid–solid) on the mechanical characteristics and microstructure of CG_700°C-based geopolymers were investigated. The findings indicated that the specimens with a liquid–solid ratio of 0.50 (G_2.0-10-0.50) exhibited a compact microstructure and attained a compressive strength of 24.75 MPa. Moreover, increasing the Na₂SiO₃/NaOH mass ratio has shortened the setting times and facilitated geopolymer gel formation, resulting in a denser microstructure and improved compressive strength. The higher NaOH concentrations of alkali activators facilitated the dissolution of CG_700°C particles, and the geopolymerization process was more dependent on the condensation of SiO₄ and AlO₄ ions, which promoted the formation of geopolymer networks. Conversely, an increase in the liquid–solid ratio from 0.50 to 0.65 had a negative impact on compressive strength enhancement, impeding the polycondensation rate. Examination through scanning electron microscopy and mercury intrusion porosimetry revealed that employing a lower Na₂SiO₃/NaOH mass ratio (G_1.2-10-0.55), smaller NaOH concentrations (G_2.0-8-0.55), and a higher liquid–solid ratio (G_2.0-10-0.65) led to the presence of larger pores, resulting in decreased 28 days compressive strength values (15.87 MPa, 13.25 MPa, and 14.92 MPa, respectively), and a less compact structure. The results suggest that the performance of CG_700°C-based geopolymers is significantly influenced by alkali activators. Full article

Although the calcination-based activation of coal gangue is important for its valorization in the form of cementitious materials, the related works mainly focus on high-quality coal gangue, neglecting its low-quality counterpart. To bridge this gap, we herein conducted the pilot-scale suspension calcination of low-quality coal gangue; explored the effects of calcination temperature, particle size, and O₂ content on the phase composition of the calcined product, kaolinite decomposition, decarbonization, and silica/alumina dissolution; and evaluated calcination-product-based cementitious materials. Under optimal conditions (temperature = 875–900 °C; particle size = 39.71–46.84 μm; and O₂ content = 12–14%), the carbon content of the calcined product equaled 1.24–1.87 wt%, and the dissolution rates of activated alumina and silica were 77.6–79.5% and 49.4–51.1%, respectively. The 28 d compressive strength (50.8–55.7 MPa) and true activity index (98.8–108.4%) of the cementitious material prepared at a calcination product dosage of 30–38 wt% met the standard of 42.5 grade cement. This study demonstrated the suitability of suspension calcination for the preparation of high-performance low-carbon cementitious materials from low-quality coal gangue, thus providing a basis for further industrialization and technological development. Full article

In this paper, a new preparation technology is developed to make high-alumina coal gangue (HACG) auxiliary cementitious admixture by calcining HACG–Ca(OH)₂ (CH) mixture. HACG powders mixed with 20 wt.% CH were calcined within a temperature range of 600–900 °C, and the thermal transformation and mineral phase formation were analyzed. The hydration reaction between activated HACG–CH mixture and cement was also investigated. The results showed that HACG experienced a conventional transformation from kaolinite to metakaolin at 600 °C and finally to mullite at 900 °C, whereas CH underwent an unexpected transformation process from CH to CaO, then to CaCO₃, and finally to CaO again. These substances’ states were associated with the dehydroxylation of CH, the chemical reaction between CaO and CO₂ generating from the combustion of carbon in HACG, and the decomposition of CaCO₃, respectively. It is the formation of a large amount of CaO above 800 °C that favors the formation of hydratable products containing Al₂O₃ in the calcining process and C-A-H gel in the hydration process. The mechanical properties of HACG–cement mortar specimens were measured, from which the optimal calcination temperature of 850 °C was determined. As compared with pure cement mortar specimens, the maximum 28-d flexural and compressive strengths of HACG–cement mortar specimens increased by 5.4% and 38.2%, respectively. Full article

In this study, the research aim is to enhance the activity index of activated coal gangue and study its activation mechanism. The activation process of coal gangue was optimized through orthogonal tests, and the Back-Propagation (BP) neural network model was improved using a genetic algorithm. With the effects of grinding duration, calcination temperature, and calcination duration, the morphological changes and phase transformation processes of coal gangue were studied at the micro and meso levels to clarify the activation mechanism. The results indicated that the effect of calcination temperature on the strength activity index of coal gangue was most significant, followed by grinding duration and calcination duration. The potential activity of coal gangue can be effectively stimulated through mechanical and thermal activation, and the content of potential active minerals in coal gangue powders was also increased. The activation process of coal gangue for the optimal scheme was obtained as grinding at 76 min first and thermal treatment at 54 min at 749 °C. As the thermal activation under 950 °C, some unstable external hydroxyls, and internal hydroxyls in kaolinite from coal gangue were removed, the Al^Ⅵ-O octahedron was destroyed, and kaolinite was transformed into spatially disordered metakaolinite with very high activity. Full article